Date 02.09.

2025
Method Statement for Material
Document Lifting/Lowering/Shifting/Handling
Activity at various station areas
(Underground & Viaduct).

Method Statement Revision 02

No.

Method Statement for Material Lifting/Lowering/Shifting/

Handling Activity at various station areas (Underground & Viaduct).

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Revision Log

Date Revision No. Page Reason for change

number(s)
0 0

02.09.2 2 Every Project Specific as per

025 Content requirement given by DMRC

Mr. Pankaj Bhatt Mr. Dhanmendra Singh Mr. Ashish Yadav

Sr. Safety Officer (BEL) Sr. Safety Officer (BEL) Project Manager (BEL)

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Prepared By Checked By Approved By

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Table of Contents

S Description Page No.

r
.
N
o
.
1 Introduction 4
4
2 Purpose
4
3 Scope
5
4 References
5-7
5 Responsibilities
7 - 10
6 Definitions
10
7 Hazard Identification and risk
assessment
10
8 Procedure
11 - 15
8 Mobile crane
.
1
16 - 18
8 HOPT
.
2
19 - 22
8 Manual Material Handling
.
3
22
8 Ownership
.
4
22
9 Management of Records
22
1 Training
0
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22
1 Review Frequency
1
22-23
1 Audits and Review
2
23
1 Deviations
3
24
1 Safety Checklist
4
25
1 Work Permit
5

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1. Introduction
Material lifting is an activity in which different type, categories and amount of
material, weight is moved, shifted, and transferred through various types of
mechanisms, mechanical equipment’s or manually by man-movement. Using of
mechanical equipment requires human interventions for load preparation and
other similar activities during material handling. Various types of material
handling activities are likely conducted from low to high scale in industries like
Underground Stations, Viaduct Works, structure erection, roofing work,
pipes/panel shifting and various similar activities. This activity possesses high
level of danger because suspended load is a hazard and material may fall during
shifting or if wrong method of work is followed in absence of written safety
procedure will likely lead to incidents like collapse of crane, erection building
etc. So, it is required that a written safety procedure is in place with respect to
handling, storage, usage, and inspection of material handling equipment.
2. Purpose
The sole purpose of this document to provide written procedure, which is
effectively demonstrate all requirements, methods, safety checks required to
strictly adhere during material handling or using any type of material handling
equipment and prevent/eliminate all possible outcomes or probability to result
in injuries or incidents.
To ensure safe and efficient handling (lifting, lowering, shifting, and storing) of
construction materials at underground station areas and elevated viaduct works
in compliance with DMRC Safety, Health & Environment (SHE) requirements.
This document will provide all requirements related to legal, international
practice which provided ALARP measures to avoid any danger with respect to
Material handling activities.
Note: This document required 100% compliance to achieve minimum risk level
and to prevent any incidents at site.

3. Scope
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The scope of this document covers all areas, locations of DMRC This SOP is
applicable to: Underground station shafts, concourse, platform, and tunnel
levels. Elevated viaduct spans, decks, and launching yards. All laydown, storage,
and access areas within project premises. and all regular, direct or third-party
contractor employees and all direct or third-party contractor
equipments/vehicles entering inside the plant premises.
4. References

 IS 13367(Part -1) :1992 -Safe use of cranes code of practice.

 IS 4579 – Safety code for material handling equipment.
 ISO 45001 standards.
 Factories Act 1948.

5. Responsibilities
5.1 Project Manager: The project Manager is responsible and accountable for
project Occupational Health and safety and for working with various
departments, employer’s representative, and assigned staff to ensure that
from project inspection to contact completion adequate resource and top
management support are provided to ensure as safe work site in accordance
with project Safety & Health plan. This includes proper staffing, financial
support, safe design, and management support for necessary action taken.
The responsibilities and duties shall be including the following:
Delegate specific responsibilities and duties to all field management staff and
ensure such function s are carried out.

 Establish and implement the project Safety & Health Policy.

 Ensure OH&S is treated as a line responsibility at all levels.
 Direct and support field management in safe execution of duties.
 Chair Safety Committee Meetings (or delegate when unavailable).

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 Review and approve Safety Management Systems, safe work practices, and
safety documents.
 Authorize and support safety incentive schemes.
 Regularly inspect the site, identify hazards, and enforce corrective measures.
 Lead accident investigations and ensure prompt implementation of
preventive actions.
 Suspend unsafe work until hazards are rectified.
 Approve project documents and ensure compliance with statutory and
contractual OH&S requirements.
 Set OH&S objectives/targets and allocate necessary resources.
 Take disciplinary action against repeated safety violations.
 Review Risk Assessments and Emergency Plans.
 Act as a key person during emergencies.
 Participate in weekly safety walks and ensure continuous improvement in site
safety culture.

5.2 Project HSE Manager: Verify certifications, conduct safety briefings, and
monitor execution.

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Project Supervisor / Banksman: Direct lifting operation, maintain exclusion zone,

and control signaling.
Operators / Riggers: Operate equipment and secure loads safely.
Third party contractor/Venders: All third partly contractor/Venders shall
stringently compliance with these requirements elaborated in this procedure. In case
of any non- conformity will result in appropriate action as per systematically
addressed by “BEL” Consequences management system. They are responsible for
communicating all hazards associated with the works to workers in most feasible way,
so they can understand easily and required to provide adequate PPEs as addressed
work risk assessment, JHA or Method statement.
Workers: shall follow proper work method during lifting activities as per mentioned
in this procedure. Workers should be aware about all risks mentioned in their work
and shall worn appropriate PPEs mentioned in this procedure.
Signalman & Rigger: Shall follow procedure to use mobile crane, best rigging practice
for safe operation of crane. Shall use only lifting tools which are tested & of
appropriate capacity. Rigging foreman/signal man shall identify himself by wearing
reflective jacket.

Lift Engineer/ Supervisor: Shall check suitability of crane referring Load chart & raise
the request in prescribed format including all details. Load Chart will be provided by
the crane supplier / contractor. Completion of mandatory requirements such as vehicle
entry permit, Risk assessment. Use tested lifting tool-tackles of appropriate capacity
(sling / synthetic belt / D shackle / tailing hook etc.). Shall prepare Lifting plans for all
critical lifts. Ensure Area/ground preparation will be done wherever required. It will be
done with consultation of SBU/Site - Civil Engineer if crane is required to position on
soft soil. (For supporting crane outriggers sufficient wooden blocks/thick metal sheets
will be placed on soft soil). Ensure toolbox talk of all movements & rigging operations.
He shall discuss rigging plan with rigger, signal man & crane operator for safe
execution of job. Ensure operating locations are far enough away from shoring,
excavations, trenches, buried utilities, foundations, etc. to eliminate the risk of collapse.

Crane Operators responsibilities: Check ground condition & position the crane.
Crane Operator shall check all interlock & safety devices are in working condition. He
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will inform his supervisor & concern plant engineer if anyone is not in working
condition. (i.e. Anti-two blocking, Safe Load Indicator). The operator must understand
its functions and limitations as well as its operating characteristics. Having a thorough
knowledge of the information contained in the crane's operating manual. Familiar with
the crane's load chart (Refer Annexure -6 for load Chart). The operator must
understand the correct meaning of all notes and warnings and be able to calculate or
determine the crane's actual net capacity for every possible configuration of the
machine. Inspecting and maintaining the crane regularly as prescribed by both the
owner and manufacturer. Informing the owner of any problems, needed maintenance,
or necessary repairs to the machine. This should be done in writing, preferably in the
machine's logbook or inspection report. Record in the log or report the details of all
inspections, maintenance, and other work done on the crane while in the field. While
any employee is touching the load or hook, there shall be no hoisting, lowering, or
traveling. At the beginning of each operator's shift, the upper limit switch (anti-two-
block) of each hoist shall be tried out under no load. Extreme care shall be
exercised; the block protection shall be kept in line. At the beginning of each operator's
shift, the upper limit switch (anti-two-block) of each hoist shall be tried out under no
load. Extreme care shall be exercised; the block protection shall be kept in line. Holding
Vehicle Fitness Certificate / copy of valid license / safety card document. Exercising the
right to refuse to operate the crane if there is cause to suspect the lift might be unsafe.
Maintaining communication with signalman & riggers.

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SAFETY ORGANIZATION CHART:

Mr. Ashish Yadav

(Project Manager)

Mr. Dharmendra Singh Occupational Health

SHE Committee Officer
(Sr. Safety Manager)

Mr. Pankaj Bhatt

(Jr. Safety Manager)

Mr. Aadansh Sangeli

(Safety Steward)

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PROJECT MANPOWER DETAILS:

Mr. Ashish Yadav

(Project Manager)

Mr. Vikash Kimothi Mr. Amarjeet Singh Mr. Rahul Kumar Mr. Karan Sharma
(Testing Commissioning (Interface Manager)
(Design Liaison Engineer) Manager) (Installation Manager)

Mr. Dharmendra Singh

(Sr. Safety Manager)

Mr. Pankaj Bhatt

(Jr. Safety Manager)

Mr. Aadansh Sangeli

(Safety Steward)

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6. Definitions
MHE: Material Handling equipment PPE: Personal Protective Equipment
Crane: A machine for lifting and lowering a load vertically and moving it horizontally,
with the hoisting mechanism as an integral part of the machine.
Pallet: A portable platform used for moving or storing freight, typically constructed to
be moved by lift truck or pallet jack. Most frequently constructed of wood or plastic.
Pallet Jack: Equipment designed for picking up and moving pallets, with forks similar
to those of a lift truck. Either electric or manual, pallet jacks are controlled by an
operator walking behind the unit, not riding on it.
Rigging Equipment: The hardware and equipment used to safely attach a load to a
lifting device. May include straps, slings, rope, Conveyor, Chain Pulley Blocks etc.
Competent Person: As per section 28 and 29 of the act and rules 60,61 and 67-A shall
mean a degree holder or a diploma holder in mechanical engineering of recognized
university or institution and has at least two years’ practical experience in examining
testing and safe working of hoists and lifts, lifting machines and lifting tolls, tackles.
Automatic safe load indicator: A device fitted to a crane, or incorporated in its
design, that automatically gives visual indication to’ the driver when the load being
lifted or carried by the crane approaches the safe working load, and that also gives a
continuous audible warning to the driver and other persons in the vicinity when the
load being lifted

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or carried exceeds the safe working load (see also 3.7 ). Under certain statutory
regulations the automatic safe load indicator should be of a type approved ,by the Chief
Inspector of Factories (see also 3.5).
Load radius indicator: A device fitted on a crane that shows the radius of the hook and
the corresponding safe working load.
Radius: The horizontal distance between the point at which the Centre of rotation of
the crane meets the ground and the vertical centerline through the hook.

Note: Always lift load gently and operate crane motions smoothly to avoid load
swinging. (A swinging load will increase the overturning moment of the cranes.) Use
steady lines where necessary and where the load presents a wind catching area. Always
travel with the load near to ground * level so load swinging can be controlled.
Safe working load: The maximum load that can be safely handled by a crane at a
specified position and under specified condition.

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Appointed person: The management of the organization requiring the lifting

operation to be undertaken should appoint a person with appropriate training and
experience who should be competent. This person should be known as the appointed
person. ’ The appointed person need not be an employee of the organization and will
not normally undertake the duties of crane driver, slinger or signaller.
Critical lift: A lift using an Mobile crane where, because of the characteristics and
properties or travel path of the load, a hoist failure or loss of control of the load could
result in a serious personal injury, serious environmental incident, serious process
safety incident, or significant disruption to operations. Critical Lift shall contain one or
more of following criteria –
a. Tandem Lift (use of two or more cranes simultaneously)
b. Capacity utilization of crane exceedingly over 85%.
Capacity loading: It will be calculated by dividing the total weight with the safe
workload at lift radius. It shall not exceed 85% of mobile crane. For capacity loading
above 85% a lifting plan is required. No capacity loading above 100% shall be allowed,
equal to 90% of load test. If Safe Load Indicator is not installed the capacity loading
shall not exceed 60%; if above a lifting plan is required. For lifting personnel, the
capacity loading must be below 50%.
Eccentric Load: Load centre of gravity does not correspond to the geometrical center,
e.g. an unevenly loaded container. In case of eccentric load for heavy loads, say above 2
Tons, center of gravity should be calculated and lifting points defined accordingly. For
light loads the most practical is to determine the center of gravity by trial and error
without lifting the load completely off the ground.
Lift Height: The height above the setting of the crane that the load must be lifted to. To
derive at the boom height the length of hook, slings and load must be added as well as
some free space above any equipment the load will be slew over.
Length x Width x Height (LxWxH): Is required for bigger equipment for deciding
lifting radius and lifting height. For a bigger surface, say above 25 m2, also wind loads
need to be considered. For small pipe spools, valves etc. this data is not required.

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Safe Workload at lift radius: Will be derived from the selected Crane Load Chart for
the calculated lift radius and boom length (Refer Annexure -6 for load Chart).
Adjustment shall be done in relation to valid load test and only 85% of the load test
value shall be considered as safe workload.
7. Hazard Identification & Risk Assessment: Conduct a documented risk assessment of
the workplace to identify hazards with using material handling equipment on site and
in line this procedure to minimize the severity of hazards. The hazard assessment
document should be reviewed periodically or as per change/addition in process,
equipment, method, or site layout.
8. Procedure
The procedure will provide guide to operate all material handling equipment in safe
manner and to appropriately handle material without sustaining any injuries or result
in any serious events. The procedure outlines the legal requirements, ABG code of
practice, inspection, usage and maintenance procedure for applicable material handling
equipment and proper technique needs to be followed during activities associated with
material handling. Following are the section wise procedure to demonstrate effective
elaboration of safe system of work or work method for material handling:

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8.1. Mobile Crane: A mobile crane is a cable-controlled crane mounted on crawlers or

rubber-tired carriers or a hydraulic-powered crane with a telescoping boom mounted
on truck-type carriers or as self-propelled models. The boom crane extendes to various
lengths to carry different amount of load as per indicated by load chart. Mobile crane
sare widely used for structural erection of buildings in industries:

 Pre-Planning:
 Follow manufacturer’s instructions before operation.
 Ensure before lifting a documented and practical implementation of HIRA, JSA is
conucted on site.
 Work should be done under possession of vallid work to permit for lifting actvtiy.
 Ensure all potential hazards are identified and incorporated in permit to work.
 All necessary information shall be available like type of material to be lift, amount of
load etc.
 A detailed and properly structured lifting plan should be available and work should be
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carried out accordingly.

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 All persons envolved in lifting activity shall posses valid written authorization, skills
and competency for the job.
 Are should be cordoned around the lifting area by calculating the maximum swinging
load or lifting radius or as per mentioned in lifting plan.
 Give attention to other activities occurring nearby lifting area, stop the work in case of
immediate danger.
 All checks related to crane shall be verified both physically and documented manner
before starting the lifting work.
 All engineers and required officer shall be present at site during lifting work.
 Inspect all lifting tools and tackles before use like wire rope, lifting belt, D-shackles,
Hooks, chains and spreader bar.
 All lifting tools, tackles, equipment, machine crane shall be TPI by competent person
before taking onto use.
 Check all emergency arrangements are in place ensure the avaibility of ambulance,
OHC center and first aider or doctors.
 Lifting Safety Procedure
 Check soil condition, ensure soil stability, firm base available for crane placement.
 Open outrigger on jack pallet to stop mobilization of crane and for stability.
 Look for overhead danger: The crane shall only be operated minimum 6 M away from
live electrical lines or away from safe arching zone whichever is higher.
 The worker shall wrap or tie the load with suitable lifting belt or web sling or wire
rope according to lifting plan or work procedure to ensure no loose arrangement shall be
present and prevent the material from falling.
 After Bundling or tying the load the worker shall clear the area before the load lifted
by crane.

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 Use tag lines on both ends, shall be tied on diaganal ends of material to prevent it from
swinging. The length of tag lines shal be adequate to maintaine safe distance from lifted
load.
 The size of the load must be combined with the height to be lifted and the radius to
ensure that the load will not become “boom-proud”.
 Center of gravity of lift: When preparing the lift and attaching the rigging it is
important to follow the Rigging Study and ensure that the CG is directly under the hook
block of the lifting crane. When a load is lifted by a crane the CG always hangs vertically
beneath the hook. If the CG is not under the hook when it is first lifted, then the load will
tilt until it is. (see Figure below). This can be a useful way of locating the CG of a load in
the field. We know that the CG is located somewhere along the vertical line through the
hook. (See Figure blow again.) We all know this exercise: the load is lifted and does not
stay horizontal. To make sure that the load stays horizontal when lifted, we either
change the lift point position of one of the slings or lengthen or shorten one of the slings
in such a way that the CG is exactly under the hook when we lilt the load.

 All actvties shall coordinated by rigger/Signaller and shall be clear communication

througout the activity.
 Shifting of materials with crane
 Please ensure above procedure plus below instructions during shifting of materials.
 During shifting ensure the load shall be low to the ground as possible.

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 Inspected the pathway before shifting id free from debris, uneven surface, openings
etc.

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 Recommended hand signals during lifting activity

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 Don’ts need to be followed during Lifting actvitiy

 Do not over ride safe working load of crane.
 Do not use crane to pull loads.
 Do not left load un-attended.
 Do not operate in rainy weathers or high wind velocity.
 Do not Operate with damaged web sling, wire rope or lifting belts.
 Do not operate crane if any leakages or detoration found.
 Do not let crane operated by un-authorized person.
 Do not left ignition key inside the crane after completion of work or when ot in use.
 Discard any wire rope used on a crane, when the visible number of broken wires in
any length of rope diameter exceeds 5% of the total number of wires in the wire rope.
 Maintenance and inspection
 Ensure preventive maintenance shall conducted as per manufacturer’s
recommendations.
 Ensure any maintenance shall never be carry out when crane is energized.
 Maintenance shall only be carried out by authorized engineer or supplier etc.
 Prior to use inspection shall be performed to ensure operational safety of crane.
 As per addressed by legal or any other law crane should be load tested by competent
person which is authorized by government bodies.

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8.2. HOPT: HOPT are widely used in industries for manual material shifting &
maneuvering activities. As for the usage of this equipment we must ensure proper
hazards are identified, and the condition of the equipment is verified before using it. In
use of wrong way, it will result in serious injuries and incidents. A pallet truck (also
known as a pump truck or pallet jack) is a wheeled trolley designed to lift and transport
pallets. The truck's tapered forks slot underneath the pallet and the pump handle can
then be used to raise and lower the load.

 HOPT safe operational procedure

 Pre-operation checks:
 Read Operators Manual and Risk assessment.
 Inspect the pallet jack in general to ensure it is in good working condition.
 Familiarise yourself with the controls before using the pallet jack and ensure they are
undamaged and responsive.
 Observe the wheels to ensure they are not worn out and no cracks are present. This
will prevent poor handling and reduces the risk of the load becoming unstable mid
journey.
 Faulty equipment must NOT be used. IMMEDIATELY report suspect equipment.
 HOPT only shall be issued to authorized workers who are trained and qualified to
operate.
 Inventory of HOPT shall be maintained, and proper checks shall be performed at
required frequency to ensure safe operation & condition.

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 All HOPT shall be TPI by competent person.

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 HOPT shall only be issued by site incharge.

 HOPT identification number and all risks related to HOPT shall be incorporated in
work permit and JSA.
 Ensure proper risk assessment is in place with respect to all HOPT procedures.
 Operational safety checks:
 Ensure the equipment is used in accordance with the manufacturer’s instructions to
ensure your safety and the safety of the people around you.
 Ensure all other personnel or bystanders are clear of the immediate work area.
 Check the route you are taking is clear and free from hazards and uneven surface
before you begin to move your load.
 Use proper lifting techniques when loading/unloading and operating the pallet jack.
 Always keep the load level as low as possible to traverse ground.
 Make sure the load is evenly distributed.
 Never exceed the advised capacity.
 Move the load slowly to ensure safety in case your surroundings change.
 Utilise two people for heavy loads - one person should push, while the other pulls.
 You should always push the load (never pull the load).
 When going down on an incline go in reverse.
 Make sure the pallet jack is lowered fully before moving the jack out.
 Keep yours and others feet clear when lowering pallet or when reversing the pallet
jack.
 Be wary of pinch points to avoid injuries to your hands.
 Manual pallet jack operation:
 Lower the pallet jack fully, using the release lever located on the handle.
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 Roll the pallet jack through the two slots on the front of the back of the pallet.
Moderate force will be needed, since the jack has to go over parts of the pallet.
 Raise the pallet jack by pumping the handle, until the pallet is clear of the floor
underneath.
 The release needs to be off; the lever should stick out horizontal from the handle.
Move the pallet to the new location, pull the pallet using the handle of the pallet jack.
 Lower the pallet jack, using the release lever.
 Remove the pallet jack from beneath the pallet. Return pallet jack to where it is stored,
so others can easily use it when they need it.
 Ending operations and clean up
 Ensure pallet jack is in sound mechanical condition and safe to operate.
 Return the pallet jack to where it is stored, so others can easily use it when they need
it.
 Maintenance must only be performed by qualified personnel in accordance with the
Maintenance section of the Operators Manual.
 Ensure all equipment has been tested and tagged as per applicable state/territory
regulations.
 This Safe Operating Procedure does not apply to any equipment that has been
modified outside the manufacturer’s specifications.

 DON’TS YOU NEED to ENSURE DURING USING HOPT:

 DO NOT operate equipment without wearing appropriate PPE.
 Do not use a jerking action to get a loaded pallet moving. NEVER place your feet under
a pallet jack. NEVER exceed the pallet jack rated load capacity.
 Never pull a loaded pallet jack, especially DO NOT use the pallet jack to transport
person’s standing/sitting on the pallet, load or an unloaded pallet jack.

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 Do not use faulty equipment. Immediately report any suspect equipment & apply a DO
NOT USE tag.
 Unauthorized persons are strictly prohibited to operate HOPT.
 Do not carry load beyond eye visibility level.
8.3. Manual Material Handling: Manual material handling (MMH) involves any action
or movement requiring workers to lift, lower, push, pull, carry, throw, move, hold or
restrain objects or equipment. Bending, stooping, squatting, kneeling, reaching and
crouching may be involved in many manual handlings of objects and/or tools.

Manual material handling tasks may expose workers to physical risk factors if these
tasks are performed repeatedly or over a long period of time, it can lead to fatigue and
injury. The main risk factors, or conditions associated with the development of injuries
in manual handling tasks include:
 Awkward posture (e.g. bending, twisting)
 Repetitive motions (e.g. bending, twisting
 Forceful exertions (e.g. carrying or lifting heavy loads)
 Pressure points grasping (contact form) loads, leaning against parts or
 surfaces that are hard or have sharp edges)

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 Static posture (e.g. maintaining fixed position for a long time)

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No.

Repeated or continual exposure to one or more of these factors initially may lead to Fatigue
and discomfort. Over time, injury to the back, shoulders, hands, wrists or Other parts of
the body may occur. Injuries may include damage to muscles, tendons, Ligaments, nerves
and blood vessels. Injuries of this type are known as Musculoskeletal disorder or MSDs.
 Material Handling Techniques
 Correct grip: The correct grip makes use of the palm of the hand and roots of the
fingers and thumb. Gripping with the fingertips shall be avoided as they will lead to
strained fingers and muscles in the forearm.
 Straight back: In order to pick up a load with a straight back one must approach the
task by flexing the hips, knees and ankles and the load must be held close to the body.
The lift is to be brought about by the powerful muscles of the leg and not the back, which
is to be kept straight throughout the movement. A bent back is a weak back and can lead
to a strained back.
 Head up: One should practice raising the top of head and this will help to maintain a
straight back an essential movement that has to be carried out prior to every lift. This
will also enable to see where you are going. Correct foot position: One should always
have the feet apart but not wider than the hips, and one foot should be in advance of the
other. This leading foot shall be in the direction one intends to move.
 Arm close to the body: Lifting carrying or pushing with the arms away from the body
results in needless strain being put on the chest, upper back and shoulder muscles. Keep
arms as close to the body as possible.
 Use your body weight: Properly employed body weight can be used in moving a load
by acting a counterbalance and thus reducing the amount of muscular effort.
 Use material handling equipment: Use material handling equipment to carry and
transfer loads/material as much as possible.
 Excessive weights: No person shall be employed in any factory to lift, carry or move
any load so heavy as to be likely to cause him injury.

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No.

Gender Load premissible to carry

Adult female 29 kgs

Adult male 55 kgs

Don’ts you need to follow during matrial lifting

 Only carry small loads, do not try to carry heavy load which have potential to sustain
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injury.

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No.

 Do not repeated one task for long time.

 Do not carry loads and travel for longer areas.
 Do not carry loads in case of any pains and sprain.
 Do not carry load without proper knowledge and understanding of lifting techniques.
 No un-authorized worker shall allowed carry out load without proper training.
9. Ownership
The ownership this program applicable to all persons involving directly or indirectly into
material handling activities. Hence ensure to provide safe handling material and
handling equipment and shall ensure all persons are trained involving material
handling.
10. Management of records
All records shall be maintained as per manufacturer’s recommendation. Maintenance
history card shall be maintained. All records shall be available if any alterations found
than shall be approved by competent person.
11. Training
All persons should be trained in material handling equipment and manual material handling
who are directly associated with the activity. They are trained enough to identify hazards
and risk in their work. Should have competency, knowledge and skill to safely organize or
perform all material handling related activities.
 All lift operators shall be trained and certified by third party.
12. Review Frequency
This procedure shall be review during change in process, equipment, machine,
incorporation of new equipment on site or as per addressed by work requirements. This
procedure shall be reviewed by once in a year to check and sustain the effectiveness with
work.
13. Audit and review

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The effectiveness and compliance of this procedure shall be verified during routine walks,
periodic audit or during inspections. Any gaps raised in audits shall be recorded and
preventive measures shall be taken to prevent reoccurrence.
14. Deviations
Any deviations observed with respect to this procedure shall be communicated and
recorded to address and make improvement to made this procedure more suitable and
reliable.

15.
Crane & Equipment Details

Description Details
Mobile Crane / Crawler Crane /
Type of Crane
Tower Crane (as applicable)
Make & Model __________
Capacity __________ MT
Boom Length __________ m
Max. Radius __________ m
Safe Working Load (SWL) As per Load Chart
Outriggers To be fully extended & levelled
Valid third-party load test &
Certificates fitness certificate available at
site

15.1 Additional Equipment: Chain pulley blocks, winches, spreader beams, D-shackles,
wire rope slings, guide ropes, lifting cages/pallets.

15. 2 Rigging Arrangement (Typical)

 Load to be secured using certified wire rope slings (min. 2 or 4 depending on load
size).
 Shackles/D-shackles to match SWL of slings.
 Use spreader beam for long/heavy items to prevent bending.
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No.

 Guide ropes to be attached to control swinging.

 Rigging to be carried out by trained riggers only.

(Rigging Drawing to be enclosed: showing load, sling angles, spreader beam, crane hook,
and guide rope arrangement – activity specific).

15.3 Lifting/Lowering Procedure

15.3.1 Pre-Lift Checks

o Verify crane position, ground stability, and outrigger extension.

o Inspect slings, shackles, and lifting tackles.
o Barricade lifting/lowering zone.
o Toolbox talk and permit clearance before operation.

15.3.2
During Lifting/Lowering

o Signalman to guide operator (radio/hand signals).

o Lift load slowly to check stability.
o Maintain sling angle ≥ 60° to avoid overload.
o Ensure no personnel under suspended load.
o For lowering, clear landing zone and control with guide ropes.

15.3.3 Post-Operation

Lower load on firm, level surface.

Remove rigging gear safely.

Inspect tackles and store properly.

6. Safety Measures

 All workers to wear PPE (helmet, gloves, shoes, reflective vest, harness at height).
 Wind speed > 10 m/s → stop viaduct lifting operations.
 Work only in adequate lighting conditions.
 Keep fire extinguisher and first-aid kit nearby.
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No.

 Emergency plan displayed at site.

7. Documentation

 Crane load chart and third-party test certificate.

 Rigging plan/drawing signed by competent engineer.
 Daily checklist of crane and lifting tackles.
 Permit-to-Work for lifting operation.

16. Annexure
 Load chart for Mobile Crane -90 Ton, Boom length 11-50 M (Typical).

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Method Statement Revision 02

No.

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Document Lifting/Lowering/Shifting/Handling
Activity at various station areas
(Underground & Viaduct).

Method Statement Revision 02

No.

. Crane & Equipment Details

Description Details
Mobile Crane / Crawler Crane /
Type of Crane
Tower Crane (as applicable)
Make & Model __________
Capacity __________ MT
Boom Length __________ m
Max. Radius __________ m
Safe Working Load (SWL) As per Load Chart
Outriggers To be fully extended & levelled
Valid third-party load test &
Certificates fitness certificate available at
site

Additional Equipment: Chain pulley blocks, winches, spreader beams, D-shackles, wire
rope slings, guide ropes, lifting cages/pallets.

4. Rigging Arrangement (Typical)

 Load to be secured using certified wire rope slings (min. 2 or 4 depending on load
size).
 Shackles/D-shackles to match SWL of slings.
 Use spreader beam for long/heavy items to prevent bending.
 Guide ropes to be attached to control swinging.
 Rigging to be carried out by trained riggers only.

(Rigging Drawing to be enclosed: showing load, sling angles, spreader beam, crane hook,
and guide rope arrangement – activity specific).

5. Lifting/Lowering Procedure

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Method Statement Revision 02

No.

16 Pre-Lift Checks
16.3 Verify crane position, ground stability, and outrigger extension.
16.4 Inspect slings, shackles, and lifting tackles.
16.5 Barricade lifting/lowering zone.
16.6 Toolbox talk and permit clearance before operation.
17 During Lifting/Lowering
17.3 Signalman to guide operator (radio/hand signals).
17.4 Lift load slowly to check stability.
17.5 Maintain sling angle ≥ 60° to avoid overload.
17.6 Ensure no personnel under suspended load.
17.7 For lowering, clear landing zone and control with guide ropes.
18 Post-Operation
18.3 Lower load on firm, level surface.
18.4 Remove rigging gear safely.
18.5 Inspect tackles and store properly.

6. Safety Measures

 All workers to wear PPE (helmet, gloves, shoes, reflective vest, harness at height).
 Wind speed > 10 m/s → stop viaduct lifting operations.
 Work only in adequate lighting conditions.
 Keep fire extinguisher and first-aid kit nearby.
 Emergency plan displayed at site.

7. Documentation

 Crane load chart and third-party test certificate.

 Rigging plan/drawing signed by competent engineer.
 Daily checklist of crane and lifting tackles.
 Permit-to-Work for lifting operation.

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Activity at various station areas
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Method Statement Revision 02

No.

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Method Statement Revision 02

No.

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